Resilient pad composite having floating reinforcing structure

ABSTRACT

The present application discloses a composite pad structure that includes a substrate bonded to a plurality of discrete, spaced-apart, resilient elements engaged to at least one reinforcing structure.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a divisional of U.S. patent application Ser.No. 12/624,881, filed Nov. 24, 2009 (pending), which claims the benefitof priority to U.S. Provisional Patent Application Ser. Nos. 61/200,188,filed Nov. 24, 2008, 61/120,758, filed Dec. 8, 2008, and 61/145,009,filed Jan. 15, 2009, the contents of which are incorporated by referenceherein in their entirety.

FIELD AND BACKGROUND OF THE INVENTION

The present invention relates to a composite material. The compositematerial comprises at least one layer of a plurality of discrete,spaced-apart elements and one or more reinforcing structure forsurrounding the elements, and at least one layer of sheeting structurecontacting either side of the layer that includes the elements andreinforcing structure surrounding the elements. The present inventionalso relates to methods of making the resilient pad composite.

Protective materials are often used by people to protect themselves frombumps, contusions, cuts, abrasions, and traumatic injury in sports andother activities. The present invention relates to resilient protectivematerials and methods for producing protective materials for use inproducts such as shoulder and chest pads, thigh and leg pads, elbowpads, shin guards, helmets, baseball chest protectors, bicycle seats,vehicles seats, chairs, carry bag straps, sports bras, etc. Theseprotective materials may be used as

Padding material is typically worn in many sports activities such asbaseball, ice hockey, lacrosse, football, basketball and so on.Protection from impact is highly desirable for an athlete. However,protective padding material may be used in applications other thanathletic garments. By way of example only, they are desirably used inheadgear, body armor, footwear, sacks, padded linings for bags andbackpacks, padding on seats, and other uses where light weight,flexible, and breathable shock absorption to protect the body is needed.The advantages of the present technology will be understood more readilyafter consideration of the drawings and the detailed description of thepreferred embodiments.

U.S. Pat. No. 4,513,449 discloses a shock absorbing athletic equipmentwhich absorbs shock by controlled transfer of air from within anenclosure to an outside enclosure. Open-celled foam material is used toact as an exhaustible reservoir of air. However, this patent does notdisclose the foam composite padding as disclosed in the presentapplication.

U.S. Pat. No. 6,743,325 discloses a flexible material that includesresilient elements joined to a flexible, stretchable substrate. However,this patent does not disclose any lattice of reinforcing material.

U.S. Pat. No. 7,235,291 discloses an expandable thermoplastic resin foamwhich has compressive strength and low flexural modulus of elasticity.However, this patent does not disclose any reinforcing structure to thefoam material.

U.S. Pat. No. 5,435,765 discloses a surfboard pad which includes anon-slip padding system. A plurality of pad members are placed on thesurfboards. However, there are no reinforcing elements that are usedwith these surfboard pads.

U.S. Pat. No. 6,519,781 discloses an energy absorbing protective pad forprotection of areas of articulation, such as joints of human body.However, no reinforcing structure is disclosed.

U.S. Pat. No. 5,766,720 discloses an elastomer absorber of impact-causedvibrations attached to a part of the device causing the vibration.However, no reinforcing structure is disclosed.

U.S. Pat. No. 5,052,053 discloses an elastic garment for aquaticactivities such as a wet suit or dry suit that provides thermalinsulation. The garment includes stretch areas having grooves with adepth dimension to increase the elasticity of the garment. However, thispatent does not disclose a resilient element surrounded with reinforcingstructure.

U.S. Pat. No. 5,836,027 discloses an integrated matrix bedding systemwhich includes an air-foam matrix assembly that has foam elementssurrounded by other structures. However, this patent deals with beddingsystems, which lies outside of the padding art of the presentapplication.

SUMMARY OF THE INVENTION

In one aspect, the present invention is drawn to a composite padstructure comprising a substrate bonded to a plurality of discrete,spaced-apart, resilient elements engaged to at least one reinforcingstructure. The reinforcing structure may include a lattice ofreinforcing material. The one or more lattices of reinforcing materialmay engage at least some of the resilient elements. Optionally, at leastone lattice of reinforcing material may engage all of the resilientelements, and additional lattice of reinforcing material engages some ofthe resilient elements. A second substrate may be bonded on oppositeside of the resilient elements. The resilient elements that are engagedto the reinforcing structure may be positioned between the first andsecond substrates.

In another aspect, the invention is drawn to a garment that includes thecomposite described above. The garment may be an athletic garment orathletic safety wear, but may include industrial or military equipmentsuch as headgear and body armor. Footwear, sacks, padded linings forbags and backpacks, padding on seats and other uses where light weight,flexible, and breathable shock absorption to protect the body are alsocontemplated for use with the inventive composite material.

In yet another aspect, the invention is drawn to a method forfabricating a composite structure for use as a resilient cushion,comprising: (i) mounting a plurality of discrete, spaced-apart,resilient elements on a first expanse of material; (ii) engaging atleast some of the resilient elements with at least one reinforcingstructure; and (iii) mounting a second expanse of material to theresilient elements opposite the first expanse of material to form thecomposite structure, wherein the at least one reinforcing structure ispositioned between the first and second expanses of material in thecomposite structure.

The step of engaging at least some of the resilient elements with areinforcing structure includes engaging the resilient elements with afirst lattice of reinforcing material and optionally engaging at leastsome of the resilient elements with a second lattice of reinforcingmaterial. Further, the first and second lattices of reinforcing materialmay be positioned between the first and second expanses of material inthe composite structure. A cutter may be used to cut a sheet ofresilient material into a cut sheet of resilient material that includesthe plurality of resilient elements and additional resilient materialthat maintains the plurality of resilient elements in a pattern. Thecutter may include a plurality of cutting elements, each defining aspace containing a biasing material, wherein after a cutting element hasbeen used to cut a corresponding resilient element, the biasing materialmay urge the corresponding resilient element away from the space. Thestep of engaging at least some of the resilient elements with areinforcing structure may occur before or after the step of mounting theplurality of resilient elements on the first expanse of material. Thereinforcing structure may be a lattice of reinforcing material thatincludes a plurality of holes, and wherein the step of engaging at leastsome of the resilient elements with a reinforcing structure comprisespushing the plurality of resilient elements out of a cut sheet ofresilient material and into the plurality of holes in the lattice ofreinforcing material. An adhesive may be used to mount the plurality ofresilient elements to either the first expanse of material, the secondexpanse of material or both the first and second expanse of material.The adhesive may be a heat activated adhesive that is activated by aheat platen.

In still another aspect, the invention is drawn to a method of making acomposite structure for use as resilient cushion comprising: (a)providing a sheet of resilient material having opposing sides; (b)applying an adhesive to either or both sides of the sheet of resilientmaterial; (c) providing a cutter having a surface and a plurality ofcutting elements extending from the surface in a predetermined pattern;(d) pressing the cutter into the sheet of resilient material, therebyforming a cut sheet of resilient material comprising a plurality ofresilient elements and an excess resilient material; (e) withdrawing thecutter from the cut sheet of resilient material; (f) providing a sheetof reinforcing material; (g) pressing the cutter, which need notnecessarily be the same cutter used to cut the resilient material, intothe sheet of reinforcing material, thereby forming a cut sheet ofreinforcing material comprising a plurality of reinforcing elements andone or more lattices of reinforcing material; (h) withdrawing the cutterfrom the cut sheet of reinforcing material; (i) separating the latticeof reinforcing material from the reinforcing elements, whereby thelattice of reinforcing material is left with a plurality of holesthrough the reinforcing material where the reinforcing elements used tobe; (j) placing the cut sheet of resilient material on top of thelattice of reinforcing material, and aligning the cut sheet of resilientmaterial so that the plurality of resilient elements are positionedabove the plurality of holes in the lattice of reinforcing material; (k)providing a pusher having a plurality of push elements that form apattern corresponding to the pattern of the resilient elements in thecut sheet of resilient material; (l) aligning the plurality of pushelements with the plurality of resilient elements, and using the pusherto push the resilient elements out of the cut sheet of resilientmaterial, whereby the plurality of resilient elements are pushed intothe plurality of holes in the lattice of reinforcing material, therebyforming a resilient material assembly comprising the plurality ofresilient elements at least partially surrounded by at least one latticeof reinforcing material; (m) placing the resilient material assemblynext to a heat platen, if heat-activated adhesive material is applied toa side of the resilient material; (n) placing a first sheet of fabric ormesh substrate onto one side of the resilient material assembly, whereinsteps (m) and (n) may be optionally reversed in order; and (o) heatingthe first fabric or mesh sheet substrate with the heat platen toactivate the adhesive on the plurality of resilient elements, wherebythe first fabric or mesh sheet substrate adheres to the plurality ofresilient elements to form the composite material.

The invention is also directed to other embodiments, wherein in step(p), optionally removing the lattice of reinforcing material so as toresult in a first fabric or mesh sheet substrate bonded to resilientelements. Alternatively, the sheet of reinforcing material may bepre-cut so as to create several lattices of reinforcing material thatmay be processed using steps (g) through (o), wherein in the alternativestep (p), some of the lattices of reinforcing material may be removedand discarded as waste material, so as to result in a first fabric ormesh sheet substrate bonded to resilient elements, only some of whichresilient elements are surrounded by at least one lattice of reinforcingmaterial. Furthermore, as an alternative to steps (g) through (i), thelattice of reinforcement material may be created without the stepsemployed above and simply cut with by means whereby the lattice ofreinforcing material is left with a plurality of holes through thereinforcing material where the reinforcing elements used to be, andcombined with the resilient elements so that the holes in the latticefit around the resilient elements.

The invention is also directed to still other embodiments to includesteps (q) placing a second sheet of fabric or mesh substrate onto theopposite side of the resilient material assembly; and (r) heating thesecond sheet of fabric or mesh substrate with the heat platen toactivate the adhesive on the plurality of resilient elements on theopposite side, whereby the second sheet of fabric or mesh substrateadheres to the plurality of resilient elements on the opposite side.

Or, alternatively, the method may include the following steps: (p)placing a second sheet of fabric or mesh substrate onto the oppositeside of the resilient material assembly; and (q) heating the secondsheet of fabric or mesh substrate with the heat platen to activate theadhesive on the plurality of resilient elements on the opposite side,whereby the second sheet of fabric or mesh substrate adheres to theplurality of resilient elements on the opposite side.

In another aspect, the invention is also drawn to a method of making acomposite structure for use as resilient cushion comprising: (a)providing a sheet of resilient material having opposing sides; (b)applying an adhesive to either or both sides of the sheet of resilientmaterial; (c) providing a cutter having a surface and a plurality ofcutting elements extending from the surface in a predetermined pattern;(d) pressing the cutter into the sheet of resilient material, therebyforming a cut sheet of resilient material comprising a plurality ofresilient elements and excess resilient material; (e) withdrawing thecutter from the cut sheet of resilient material; (f) removing adhesivelayer from the excess resilient material on the first side of the cutsheet of resilient material, leaving adhesive layer on the resilientelements; (g) bonding a first fabric or mesh substrate to the first sideof the cut sheet of resilient material resulting in bonding between theresilient elements to the first substrate; and (h) separating the excessresilient material from the cut sheet of resilient material, leaving theplurality of resilient elements bound to the first substrate.

The above process may optionally include additional steps (i) placing asecond sheet of fabric or mesh substrate onto the second side of theresilient material assembly; and (j) heating the second sheet of fabricor mesh substrate with the heat platen to activate the adhesive on theplurality of resilient elements on the second side, whereby the secondsheet of fabric or mesh substrate adheres to the plurality of resilientelements on the second side.

Alternatively, the above process may include additional steps of (i)providing a sheet of reinforcing material; (j) pressing a cutter intothe sheet of reinforcing material, thereby forming a cut sheet ofreinforcing material comprising a plurality of reinforcing elements andat least one partial or full lattice of reinforcing material (k)withdrawing the cutter from the cut sheet of reinforcing material; (l)separating the lattice of reinforcing material from the reinforcingelements, whereby the lattice of reinforcing material is left with aplurality of holes through the reinforcing material where thereinforcing elements used to be; and (m) engaging at least one partialor full lattice of reinforcing material to the resilient elements in(h).

Optionally, after engaging at least one partial or full lattice ofreinforcing material to the resilient elements in (h) as described instep (m), at least one partial lattice of reinforcing material may beremoved, leaving at least one partial lattice of reinforcing materialengaged to the resilient elements.

Optionally, the above method may include the following additional steps:(n) placing a second sheet of fabric or mesh substrate onto the secondside of the resilient material assembly; and (o) heating the secondsheet of fabric or mesh substrate with the heat platen to activate theadhesive on the plurality of resilient elements on the second side,whereby the second sheet of fabric or mesh substrate adheres to theplurality of resilient elements to form the composite material, whereinthe at least one partial or full lattice of reinforcing material ispositioned between the first and second sheets of fabric or meshsubstrate.

In another aspect, the invention is also drawn to a method of making acomposite structure for use as resilient cushion comprising: (a)providing a sheet of resilient material having opposing sides; (b)applying an adhesive to either or both sides of the sheet of resilientmaterial; (c) providing a cutter having a surface and a plurality ofcutting elements extending from the surface in a predetermined pattern;(d) pressing the cutter into the sheet of resilient material, therebyforming a cut sheet of resilient material comprising a plurality ofresilient elements and excess resilient material; (e) withdrawing thecutter from the cut sheet of resilient material; (f) covering the excessresilient material with a blocking sheet of a substrate with a patternso that only the resilient elements are free to bond to any othersubstrate; (g) bonding a first fabric or mesh substrate to the firstside of the cut sheet of resilient material resulting in bonding betweenthe resilient elements to the first substrate; and (h) separating theexcess resilient material from the cut sheet of resilient material,leaving the plurality of resilient elements bound to the firstsubstrate.

In yet another aspect, the invention includes a method of making acomposite structure for use as resilient cushion comprising: (a)providing a sheet of resilient material having opposing sides; (b)providing a cutter having a surface and a plurality of cutting elementsextending from the surface in a predetermined pattern; (c) pressing thecutter into the sheet of resilient material, thereby forming a cut sheetof resilient material comprising a plurality of resilient elements andexcess resilient material; (d) withdrawing the cutter from the cut sheetof resilient material; (e) coating resilient elements selectively withadhesive; (f) bonding a first fabric or mesh substrate to the first sideof the cut sheet of resilient material resulting in bonding between theresilient elements to the first substrate; and (h) separating the excessresilient material from the cut sheet of resilient material, leaving theplurality of resilient elements bound to the first substrate.

These and other objects of the invention will be more fully understoodfrom the following description of the invention, the referenced drawingsattached hereto and the claims appended hereto.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description given herein below, and the accompanying drawingswhich are given by way of illustration only, and thus are not limitativeof the present invention, and wherein;

FIG. 1 is a drawing of an application of the resilient pad compositeused in an undergarment.

FIG. 2 is an exploded view of the resilient pad assembly, which includesthe resilient elements, the partial reinforcement lattice and a support.

FIG. 3 is a partial cut away view of the resilient pad assembly, whichincludes the resilient elements, the partial reinforcement lattice and asupport.

FIG. 4 is a side view of the resilient pad assembly, which includes theresilient elements, the partial reinforcement lattice and a support.

FIG. 5 is an exploded view of the resilient pad assembly, which includesthe resilient elements, the full reinforcement lattice and a support.

FIG. 6 is a partial cut away view of the resilient pad assembly, whichincludes the resilient elements, the full reinforcement lattice and asupport.

FIG. 7 is a side view of the resilient pad assembly, which includes theresilient elements, the full reinforcement lattice and a support.

FIG. 8 is an exploded view of the resilient pad assembly, which includesthe resilient elements, the full and partial reinforcement lattice and asupport

FIG. 9 is a partial cut away view of the resilient pad assembly, whichincludes the resilient elements, the full and partial reinforcementlattice and a support.

FIG. 10 is a side view of the resilient pad assembly, which includes theresilient elements, the full and partial reinforcement lattice and asupport.

FIG. 11 is an embodiment of the invention where the resilient element iscone shaped.

FIG. 12 is an embodiment of the invention where the resilient element iscored cylinder shaped.

FIGS. 13A-13D is a sectional side view of the resilient pad assembly,where the resilient assembly is surrounded by reinforcement lattice. Theresilient element is shaped as A. a cylinder; B. cone; C. a cylinderwith a constricted end section; D. a cylinder with constriction near themiddle of its body.

FIG. 14 is an exploded and perspective view of a sheet of resilientmaterial positioned between a cutter and a work surface.

FIG. 15 is a sectional side view of a sheet of resilient materialpositioned beneath a cutter on a work surface.

FIG. 16 is a sectional side view of a cutter cutting a sheet ofresilient material on a work surface.

FIG. 17 is a sectional side view of a cut sheet of resilient materialpositioned between a cutter and a work surface.

FIG. 18 is a sectional side view of a sheet of reinforcing materialpositioned beneath a cutter on a work surface.

FIG. 19 is a sectional side view of a cutter cutting a sheet ofreinforcing material on a work surface.

FIG. 20 is a sectional side view of a cut sheet of reinforcing materialpositioned between a cutter and a work surface.

FIG. 21 is a sectional side view of reinforcing elements being removedfrom a cut sheet of reinforcing material to form a lattice ofreinforcing material.

FIG. 22 is a perspective view of a lattice of reinforcing material.

FIG. 23 is an exploded and perspective view of a cut sheet of resilientmaterial and a lattice of reinforcing material positioned between apusher and a die.

FIG. 24 is a sectional side view of a cut sheet of resilient materialand a lattice of reinforcing material beneath a pusher on a die.

FIG. 25 is a sectional side view of a pusher pushing resilient elementsfrom the cut sheet of resilient material and into the lattice ofreinforcing material to form a resilient material assembly.

FIG. 26 is a sectional side view of a resilient material assembly on adie.

FIG. 27 is a sectional side view of a resilient material assembly beingremoved from a die.

FIG. 28 is a sectional side view of the resilient material assembly andan expanse of cloth or mesh material positioned between a work surfaceand a heat platen.

FIG. 29 is a sectional side view of a first composite material beingformed with a heat platen.

FIG. 30 is a sectional side view of the first composite material.

FIG. 31 is a sectional side view of a second composite material formedfrom the first composite material.

FIG. 32 is a sectional side view of the second composite material and anexpanse of cloth or mesh material positioned between a work surface anda heat platen.

FIG. 33 is a sectional side view of a third composite material beingformed from the second composite material with a heat platen.

FIG. 34 is a sectional side view of the third composite material.

FIG. 35 is a sectional side view of the second composite material, alattice of reinforcing material and an expanse of cloth or mesh materialpositioned between a work surface and a heat platen.

FIG. 36 is a sectional side view of an intermediate step in forming afourth composite material with a heat platen.

FIG. 37 is a sectional side view of the fourth composite material beingformed with a heat platen.

FIG. 38 is a sectional side view of the fourth composite materialshowing partial reinforcement.

FIG. 39 is a sectional side view of the first composite material and anexpanse of cloth or mesh material positioned between a work surface anda heat platen.

FIG. 40 is a sectional side view of a fifth composite material beingformed with a heat platen.

FIG. 41 is a sectional side view of the fifth composite material.

FIG. 42 is a sectional side view of the first composite material, alattice of reinforcing material and an expanse of cloth or mesh materialpositioned between a work surface and a heat platen.

FIG. 43 is a sectional side view of a sixth composite material beingformed from with a heat platen.

FIG. 44 is a sectional side view of the sixth composite material showingfull reinforcement.

FIG. 45 depicts the “peeling off” or removal of the adhesive layer fromthe excess resilient material portion of the resilient material.

FIG. 46 is sectional side view of the cut resilient material and anexpanse of cloth or mesh material positioned between a work surface anda heat platen.

FIG. 47 is a sectional side view of resilient material/substratecomposite material being formed with a heat platen.

FIG. 48 is a sectional side view of the second composite material.

FIG. 49 is a sectional side view of the first composite material formedfrom the second composite material.

FIG. 50 is a sectional side view of the second composite material and anexpanse of cloth or mesh material positioned between a work surface anda heat platen.

FIG. 51 is a sectional side view of a third composite material beingformed from the second composite material with a heat platen.

FIG. 52 is a sectional side view of the third composite material.

FIG. 53 is a sectional side view of the second composite material, alattice of reinforcing material and an expanse of cloth or mesh materialpositioned between a work surface and a heat platen.

FIG. 54 is a sectional side view of an intermediate step in forming afourth composite material with a heat platen.

FIG. 55 is a sectional side view of the fourth composite material beingformed with a heat platen.

FIG. 56 is a sectional side view of the fourth composite material.

FIG. 57 is a sectional side view of the first composite material, alattice of reinforcing material and an expanse of cloth or mesh materialpositioned between a work surface and a heat platen.

FIG. 58 is a sectional side view of a sixth composite material beingformed with a heat platen.

FIG. 59 is a sectional side view of the sixth composite material.

FIG. 60 is perspective view of a sheet of cut resilient material coatedwith an adhesive on its first side.

FIG. 61 is perspective view of a sheet of cut resilient material coatedwith an adhesive on its first side only on the resilient elements.

FIG. 62 is perspective view of the formation of the second compositematerial in which the first side of the resilient elements is adhered tothe cloth or mesh material and the excess resilient material is removed.

FIG. 63 is perspective view of the second composite material.

FIG. 64 is perspective view of the second composite material and apartial lattice of reinforcing material being fitted together.

FIG. 65 is perspective view of a partial lattice of reinforcing materialfit on to the second composite material.

FIG. 66 is side/perspective view of a partial lattice of reinforcingmaterial fit on to the second composite material.

FIG. 67 is perspective view of the second composite material and a fulllattice of reinforcing material being fitted together

FIG. 68 is perspective view of a full lattice of reinforcing materialfit on to the second composite material.

FIG. 69 is perspective view of full and partial lattices of reinforcingmaterial fit on to the second composite material.

FIG. 70 is side/perspective view of a full and partial lattice ofreinforcing material fit on to the second composite material.

FIG. 71 is perspective view of the formation of fourth composite byadhering a cloth or mesh material to the second side of the resilientelements, in which the resilient elements and the lattice of reinforcingmaterial are sandwiched between the cloth or mesh material layers.

DISCLOSURE OF THE INVENTION

In the present application, “a” and “an” are used to refer to bothsingle and a plurality of objects.

In one aspect, the composition of the resilient elements may includewithout limitation some type of resilient material, such as foam,rubber, elastomer, plastic, and so forth (including a combination ofsuch materials). Functionally, the resilient elements may act as acushion against impact, or provide insulation to heat, depending on thetypes and material of the resilient element that is made.

The shape of the resilient element may be in any form, so long as it isable to be reinforced by the reinforcing structure. While the resilientelements shown in the drawings are depicted as cylindrical through itscross-sectional view, each resilient element may have the same or adifferent shape than the other resilient elements, so long as aplurality of the resilient elements, or the desired subset of theresilient elements, can be reinforced by the selected reinforcementlattice(s). Typically, the resilient elements will be cylindrical, butother regular and irregular shapes may be made such as, withoutlimitation, a block shape, a conical structure, a tapered cylindricalstructure or a tapered block structure, or a cylinder, cone, or blockhaving a constricted middle section, which may allow for greater“grabbing” by the element reinforcing structure by allowing the elementreinforcing structure to contact the constricted middle portion of thecylinder or block. It is understood that to form these various shapes,each cutting elements will have a shape corresponding to the desiredshape of its corresponding resilient element.

All manner of imaginable variation in size and shape of the resilientelement is contemplated in the invention. It is to be noted that theheight of the resilient elements may vary in a composite. For instance,the height may be made greater in areas where especially high impact isexpected. In other words, there is no requirement that the height of theresilient elements as well as the resulting composite pad be uniform.The variability in height may be aesthetic or may serve a physicalfunction. Regarding the shape of the resilient elements, while thepresently exemplified shapes include oval and circular resilientelements in top plan view, other designs are contemplated within thepresent invention, such as various polygons, such as triangles, squares,pentagons, hexagons, heptagons, and so forth, including, dumbbellshapes, other irregular shapes or a mixture of any of these variousshapes that can be imagined according to desirability. The shapes do notneed to be uniform within a single composite, and in certain situations,a variety of different shapes and sizes of the resilient elements may beused. It is to be understood that the variability of the shape of theresilient elements and how closely spaced apart or how densely orloosely positioned the resilient elements are in relation to each other,may affect the stretchability and breathability of the assembly.

In another aspect, the element reinforcing structure may be made of avariety of different material, including without limitation, foam,neoprene, natural or synthetic leather, plastic, rubber (including,without limitation, latex and silicone), or synthetic fabric, dependingon its use. In one aspect of the invention, the reinforcing structuremay be made of a different material from the sheeting structure,depending on the use of the composite. For example, if it is desiredthat the element reinforcing structure be stable and not be stretchableas compared with the sheet structure, then the material for thereinforcing structure and the sheeting structure should be so chosen asto result in these properties. An example of this situation occurs infor instance, an elbow or knee pad, where the sheeting structure may beflexible but that the element and the element reinforcing structureshould not be as flexible so that optimum cushioning may be provided tothe angled elbow or knee through the stable placement of the element tothe angled area.

The element reinforcing structure may be a hard material, which wouldrestrict movement of the reinforcing structure within its environment,such as without limitation, hard foam, leather, rubber, or a plasticsheet.

If, on the other hand, it is desired that the reinforcing material bemore stretchable than the resilient material, then a more stretchablematerial may be chosen for the element reinforcing material. It isunderstood that the material to be chosen to effectuate the desiredstretching properties are available to a person of skill in the art.

The element reinforcing structure may be shaped flat or curved. Thematerial for the element reinforcing structure may be adjusted toincrease or decrease absorbency, breathability, stretchability, ortensile strength. The element reinforcing structure may include holes oropenings to increase or decrease breathability, stretchability, and aircirculation. Any manner of properties for the element reinforcingstructure in contemplated within the purview of the invention.

Regarding the lattice of reinforcing material or otherwise referred toas reinforcement member, several of the lattices may be used together.Some may be stacked on top of each other interconnecting with otherlattices on the same plane, or to lattices on different planes throughengagement to common resilient elements, and so forth. Whereas thepresent application exemplifies certain shapes of lattices, a variety oflattice shapes for physical, functional or aesthetic purposes arecontemplated. Lattices with cut-outs and other various shapes and sizes,for example, are contemplated within the invention. Indeed any shapeimaginable can be made of the resilient elements and the lattice ofreinforcing structure can be used in the composite pad of the invention.

In another aspect of the invention, the sheeting structure may betypically composed of a fabric, which may be natural or syntheticfabric. Alternatively, the sheeting structure may be flexible or pliableplastic, or latex, silicone, or other rubber material, or made ofsynthetic fiber, which impart breathability and stretchability to theassembly.

In a specific embodiment, the present invention is directed to aprotective pad construction for use on, amongst other things, protectivegarments, headgear, athletic clothing, body armor, and other uses wherelight weight, breathable, stretchable, contourable shock absorption tonot only protect the body but also as a padding is needed. Footwear,bags, backpacks, sacks, seats, and seat cushions are some of the manyproducts that would benefit from combining with the inventive compositepad. The foam pad of the present invention is constructed in accordancewith the preferred embodiments illustrated in the drawings.

A typical application of the inventive resilient or foam pad is shown inFIG. 1, where a representative undergarment is indicated generally at10, and may be of a type used by athletes in football, baseball,basketball, etc. The undergarment is illustrated to show just one use ofthe inventive foam pads, and is not intended to limit application of thefoam pad of the present invention to be placed only on undergarments.The inventive pads may be placed permanently or by reversible attachmenton any object for which protection of the wearer from impact force isdesired. Such reversible attachment may be carried out by withoutlimitation zippers, velcro and so forth. Turning to FIG. 1, the garmentincludes an upper portion 12 for fitting around the waist and hips, andleg portions 14 and 16 which extend downwardly approximately midwayalong the thighs. The undergarment is constructed of suitable materialfor providing compression against the body, to aid in minimizing fatigueand strain during athletic activities. Shown mounted on the undergarmentare protective pads, such as a hip pad indicated at 18 and a thigh padindicated at 20. The provision of hip and thigh pads on undergarments isconventionally used, and FIG. 1 is merely provided to show where theinventive foam pads might typically be placed. Of course, foam padscould be placed on other areas of the undergarment, such as withoutlimitation, on the backside and groin areas. And further foam pads couldbe placed on helmets, backpack linings, equipment linings, footwear,seats, and so forth.

The inventive composite material may comprise a laminated structureincluding a substrate, a plurality of discrete, spaced-apart resilientelements or foam elements and a reinforcing structure or lattice forsurrounding selected resilient or foam elements, and at least an upperlayer of fabric or mesh material. This foam pad or “package,” of desiredconfiguration, can be adapted for integration in numerous applicationsas has been described above.

Resilient Pad Composite with Partial Reinforcement

For convenience, the resilient pad composite material comprisingelements of the invention will be referred to hereinafter in a specificembodiment as “foam pad”. It is to be understood that while the presentapplication describes the present invention as a “foam pad”, theinvention should not be limited to “foam” element, as other material maybe used, and further the invention should not be necessarily limited toa “pad”, as other uses of the composite are contemplated in theinvention, such as elbow and knee guards and protectors, shin guards,shoulder guards and protectors, and chest protectors for athletes;exercise mats; back panels for backpacks, shoulder straps, and paddingfor weightlifting belts; helmet and hat linings, head protectors;linings for body armor; shoe midsoles, shoe outsoles, shoe inner lining,and other applications where lightweight, breathable, stretchable,contourable, flexible protective cushioning is desired. As shown in FIG.2, a foam pad with partial reinforcement is shown in an exploded view.The foam pad includes an upper layer of fabric or mesh materialgenerally indicated at 22, an intermediate or partial reinforcementmember 24 which may be thought of as a “cage,” because it capturesselected ones of foam elements. A substrate of fabric or mesh materialis indicated at 26, and a plurality of discrete, spaced-apart foamelements are indicated at 28. The foam elements, in this example areshown as being optionally circular or oval in cross-section and areoptionally cylindrical in form.

The foam pads may be made of suitable foam material, such as EVA, PE,Neoprene, or other foam material. In the exploded view in FIG. 2, anupper surface of the foam elements is exposed, it being understood thatthe lower surface has been optionally suitably bonded, by appropriateadhesive material, in a laminating process to the upper surface ofsubstrate 26. The upper surface of the foam elements, such as indicatedat 28 a is also provided with adhesive material which upon suitableapplication of heat can be laminated to mesh material 22.

Partial reinforcement member or lattice 24 is dimensioned with across-sectional area which is less than that of the area occupied byresilient or foam elements 28 on substrate 26. Reinforcement member 24is provided with a plurality of openings, in this case circular openings30 which are dimensioned with a diameter greater than the diameters offoam elements 28.

As can be seen, reinforcement member 24 is dimensioned with a width Wand a length L less than the width and length of the area occupied byfoam elements 28 on substrate 26. In assembly, reinforcement member 24is displaced over a region of the expanse of foam elements 28, as shownin FIG. 3 so that certain of the foam elements are confined withincorresponding apertures of reinforcement member 24 while remainder onesof the foam elements remain unconstrained.

As shown in FIG. 3, there are outer rows of foam elements 28 which arenot constrained by reinforcement member 24. This can be appreciatedfurther by viewing FIG. 4, which is a cross-sectional view taken alonglines 4-4, where it can be seen that when reinforcement member 24 isdownwardly positioned over aligned ones of foam elements 28, a portionof each of the foam elements extends above the upper surface ofreinforcement member 24. Outer rows of foam elements 28 are notconstrained by reinforcement member 24. As also shown in FIG. 4, thecomposite are sandwich construction includes upper layer 22 adhered ontothe upper surface of foam elements 28. Upper surface 22 is adhered tothe foam element in a lamination process; as mentioned previously,substrate 26 was adhered to the bottom surface of foam elements by alamination process as well.

The construction as described above, with inclusion of a partialreinforcement member provides distinct advantages when the compositefoam pad is utilized for protection. While FIGS. 2-4 illustrate a foampad having a generally rectangular configuration, and with partialreinforcement member 24 also being generally rectangular, it should beappreciated that other configurations, such as circular, oblong,triangular, etc. could be readily provided, depending upon theparticular placement of the foam pad. For example, if the composite foampad is placed on a thigh or hip, it may well have a differentconfiguration than if it is placed on headgear, for protection on theelbow, knee, shin, or other area of the body. Partial reinforcement, asdescribed above, enables a composite foam pad to provide severalimportant advantages. First, designation of a specific area to becovered by the reinforcement member enables the foam elements on thefabric, outside of the reinforcement member to move along with thefabric as it is stretched. This stretching may occur, depending uponbody part movement, such as the leg, arm or wherever the composite foampad is provided. The foam element captured within the reinforcementmember of course will not move with the stretching action nearly as muchas the foam elements outside of the reinforcement member. Thereinforcement member also provides additional shock absorbingcapability. As shown in FIG. 4, reinforcement member 24 is dimensionedso that a portion of the foam elements 28 optionally extend above theupper surface of the reinforcement member. This enables the foamelements to be compressed upon impact, but the compression is limited ina downward direction by the surface of the reinforcement member.However, the height of the resilient elements may be varied and is notlimited to a height extending above the upper surface of thereinforcement member. The reinforcement member may be constructed of aless resilient material and therefore provides enhanced shock absorbingeffect. Apertures 30 provided in reinforcement member 24 optionally maybe dimensioned with a diameter greater than that of foam elements 28, sothat there is some play of each foam element within its associatedaperture 30 in the composite foam pad. Greater differences in thediameter allow more air to circulate within the pad resulting in a padwith greater flexibility and with enhanced circulation or “breathing”.

Thus, from the description above, it can be seen that the partialreinforcement member 24 provides extra protection, while still enablinga composite foam pad to stretch. With this general construction in mind,it can be appreciated that reinforcement member 24 may be designed tocustom specifications and protect a given area while allowing anotherarea to stretch where articulation is necessary. The combination ofbreathability can be insured by areas not covered by the reinforcementmember and the reinforcement member itself may provide an enhancedamount of insulation. Moreover, the foam elements such as indicated at28 and the reinforcement member 24 may be suitably provided with a boreextending therethrough which can enhance circulation, again depending onthe particular application of the foam pad.

While not specifically shown in FIG. 2, multiple reinforcement membersor lattices may be provided at selected locations to capture selectedones of the foam elements. Reinforcement lattices, as illustrated above,and in particular with respect to FIG. 4, can be seen to provide an areaof circulation between the upper layer 22 and the top surface of thereinforcement lattice. In essence an air chamber is provided, and thiscirculation may be important for comfort. Moreover, the foam elementsfirst absorb an impact and then the reinforcement member absorbs furtherimpact as the foam elements depress, therefore absorbing more energyfrom an impact. The reinforcement member also maintains those foamelements captured therewithin in a substantially uniform position. Thismay be important for protecting a certain area of the body; a portion ofthe foam pad may stretch to accommodate movement but those foam elementscaptured within the reinforcement member maintain a substantiallyuniform orientation with respect to that body portion sought to beprotected.

The reinforcement member also will help prevent damage to those foamelements captured within the reinforcement member; for example, certaintypes of impact may cause foam elements to be compressed toward oneanother, and could cause damage to them. With the reinforcement memberin position, the foam elements captured within the reinforcement memberare spaced apart and maintained apart, thereby enhancing their integrityand wear.

Resilient Pad Composite with Full Reinforcement

The present invention also contemplates a composite foam pad in whichthere is full reinforcement, and that construction is shown in theexploded view of FIG. 5. Specifically, an intermediate fullreinforcement member or cage, generally indicated at 25 is provided withapertures for alignment for receiving therewithin foam elements 28 in acomposite structure. The foam pad as optionally fully laminated is shownin FIG. 6, and as can be seen, along with FIG. 7, the foam elementsoptionally extend above the surface of the reinforcement member 25 andfabric 22 is suitably laminated to provide the composite construction.However, the height of the resilient elements may be varied and is notlimited to a height extending above the upper surface of thereinforcement member. It is recognized that the distinction between a“partial” or “full” reinforcement member may blur, depending upon thenumber of foam elements and the specific outline or configuration of thereinforcement member. For example, while FIG. 6 shows a fullreinforcement member which contemplates capturing substantially all ofthe foam elements, a reinforcement member may be constructedintermediate in size, as say between reinforcement members 24 and 25.Again, the relative dimensions of a reinforcement member depend upon theneed and where the protection is needed. Of course with the fullreinforcement member as shown in FIG. 6, stretching of the fabric islimited significantly from the capability of the fabric shown in FIG. 3,which shows partial reinforcement member. It is understood that areinforcement member (whether partial or full) may link with anotherreinforcement member through engagement by another reinforcement memberto shared resilient elements. For instance, reinforcement memberspositioned side by side on a resilient sheet may be more stably linkedtogether by placing another reinforcement lattice stacked over thereinforcement members below by engaging the stacking reinforcementlattice to resilient elements common to the reinforcement memberspositioned on the resilient pad.

Resilient Pad Composite with Partial and Full Reinforcement

As shown in FIG. 8, a foam pad with partial and full reinforcement“stacked” is shown in an exploded view. The foam pad includes an upperlayer of fabric or mesh material generally indicated at 22, and twointermediate members, such as partial reinforcement member 24 and fullreinforcement member 25. As shown in the composite structure in FIGS. 9and 10, reinforcement member 24 is mounted on top of reinforcementmember 25 and in that area of overlap, compressibility of foam elements28 is greatly diminished. While there are areas above reinforcementmember 25 where reinforcement member 24 does not repose, and morecompression of adjacent foam elements is maintained, it should beappreciated that the “stacked” arrangement of the reinforcement membersprovides a further enhanced area of impact protection. Depending uponthe relative sizes of the reinforcement members, there can be a stackedconfiguration of “partial” cages which would enable outlining areas ofthe mesh or fabric to still provide stretchability. The point here isthat there are numerous types of combinations and configurations whichcan be provided with the multiple, stacked reinforcement memberconfiguration shown. What is more, with the concept of stacking,portions of the composite foam pad may be reinforced with stackedreinforcement members while other portions may have a partialreinforcement member. Choice of perimeters and design enablecustomization of a foam pad with reinforcement and stability as desired.FIG. 11 shows a different type of foam element construction, in thiscase a conical configuration which would allow a reinforcement member tobe received thereover but provide further air space for breathability.Breathability is also enhanced by the foam element construction shown inFIG. 12, namely, that a bore may be optionally constructed through eachfoam element such that breathability between the upper fabric 22 andlower substrate 26 is provided.

FIGS. 13A-13D show examples of different configurations of foam elementswhich may be utilized in a cage construction. FIG. 13A shows anelongated foam element, and the arrows indicate that a cage may havemovement caused by impact or relaxing of impact. FIG. 13B shows anelongated conical foam element and FIG. 13C shows a foam element formedof a wider base portion. FIG. 13D shows a pair of truncated cones facingone another which would tend to localize a cage intermediate the top andbottom of the resilient or foam element, rather than near the topsurface of the substrate or adjacent the bottom surface of the upperlayer.

It will be noted that in FIG. 4, partial reinforcement member 24 isshown disposed against substrate 26. However, it should be recognizedthat the reinforcement member may move vertically or horizontally whileengaged to the resilient elements or “jiggle” or “float” between upperlayer 22 and substrate 26, depending on the height of the reinforcementmember in relation to the resilient elements. There is more “float” or“jiggle” if the height of the resilient element is higher. This alsodepends, of course, upon the configuration of the foam elements, therelative friction between the foam elements and the openings of thereinforcement member and the degree and force of impact, if and whenthat occurs. Similarly, while FIG. 7 shows full reinforcement member 25positioned against substrate 26, that reinforcement member may move orfloat between upper layer 22 and substrate 26. In the embodiment shownin FIG. 10, depending upon the relative thicknesses of partialreinforcement member 24 and full reinforcement member 25, floatingaction or movement of the “stacked” reinforcement members may be limitedto a lesser degree than if a single reinforcement member, whetherpartial or full, were utilized.

A First Process for Making the Resilient Composite Pad

The present invention also relates to a process for making compositepads with no reinforcement, partial reinforcement, full reinforcement,and both partial and full reinforcement, such as depicted in FIGS. 1-13.In one exemplified method, the process generally comprises:

(a) providing a sheet of resilient material having opposing sides;

(b) applying an adhesive to either or both sides of the sheet ofresilient material;

(c) providing a first cutter having a surface and a plurality of cuttingelements extending from the surface in a predetermined pattern, whereeach cutting element has a shape defining an internal space, wherein theplurality of cutting elements are spaced apart from one another todefine a contiguous space surrounding and between the plurality ofcutting elements, and the internal spaces and the contiguous space areoptionally filled with biasing material;

(d) pressing the first cutter into the sheet of resilient material,thereby forming a cut sheet of resilient material comprising a pluralityof resilient elements and an excess resilient material, where eachresilient element has a shape corresponding to the shape of the internalspace of its corresponding cutting element, the plurality of resilientelements form a pattern corresponding to the predetermined pattern ofthe plurality of cutting elements, and the excess resilient material hasa shape corresponding to the shape of the contiguous space;

(e) withdrawing the cutter from the cut sheet of resilient material,whereby the biasing material urges the plurality of resilient elementsand the excess resilient material away from the internal spaces withinand the contiguous space surrounding the plurality of cutting elements,thereby leaving the cut sheet of resilient material with the cutportions of the resilient elements surrounded by the excess resilientmaterial;

(f) separately providing a sheet of reinforcing material, which may beoptionally processed using the methods described in steps (g)-(i),however, the methods of processing a reinforcement lattice is notlimited to carrying out the following steps, so long as at least onereinforcement lattice is obtained so as to be combinable with theresilient elements to form the inventive composite pad;

(g) pressing a second cutter into the sheet of reinforcing material,thereby forming a cut sheet of reinforcing material comprising aplurality of reinforcing elements and at least one lattice ofreinforcing material, where each reinforcing element has a size andshape corresponding to the predetermined size and shape of the cuttingelements, the plurality of reinforcing elements form a patterncorresponding to the predetermined pattern of the plurality of cuttingelements, and the lattice of reinforcing material has a shapecorresponding to the shape of the contiguous space;

(h) withdrawing the second cutter from the cut sheet of reinforcingmaterial, whereby if the biasing material is optionally used, thebiasing material urges the plurality of reinforcing elements and thelattice of reinforcing material away from the internal spaces within andthe contiguous space surrounding the plurality of cutting elements, andthereby leaves the cut sheet of reinforcing material with the cutportions of the reinforcing elements optionally surrounded by thelattice of reinforcing material;

(i) separating the lattice of reinforcing material from the reinforcingelements, whereby the lattice of reinforcing material is left with aplurality of holes through the reinforcing material where thereinforcing elements used to be;

(j) providing a die comprising a surface having a plurality of openingsdefined therein, where the surface surrounding the openings has a shapesubstantially corresponding to the shape of the excess resilientmaterial in the cut sheet of resilient material, and to the shape of thelattice of reinforcing material, and where at least a plurality ofopenings form a pattern corresponding to the pattern of at least some ofthe resilient elements in the cut sheet of the resilient material;

(k) placing at least one lattice of reinforcing material on the die andaligning the lattice of reinforcing material so that the plurality ofholes in the lattice of reinforcing material are positioned above theplurality of openings in the die;

(l) placing the cut sheet of resilient material on top of the lattice ofreinforcing material, and aligning the cut sheet of resilient materialso that the plurality of resilient elements are positioned above theplurality of holes in the lattice of reinforcing material, and above theplurality of openings in the die;

(m) providing a pusher having a plurality of push elements that form apattern corresponding to the pattern of the resilient elements in thecut sheet of resilient material;

(n) aligning the plurality of push elements with the plurality ofresilient elements, and using the pusher to push the resilient elementsout of the cut sheet of resilient material, whereby the plurality ofresilient elements are pushed into the plurality of holes in at leastone lattice of reinforcing material and others into the plurality ofopenings directly in the die, thereby forming a resilient materialassembly comprising the plurality of resilient elements at leastpartially surrounded by at least one lattice of reinforcing material;

(o) removing the resilient material assembly from the die, and placingthe resilient material assembly below a heat platen, if heat-activatedadhesive material is applied to a side of the resilient material;

(p) placing a sheet of fabric or mesh material or any other suitablematerial onto one side of the resilient material assembly, wherein steps(o) and (p) may be reversed; and

(q) heating the fabric or mesh sheet or any other suitable material withthe heat platen to activate the adhesive on the plurality of resilientelements, whereby the fabric or mesh material or any other suitablematerial adheres to the plurality of resilient elements to form thecomposite material.

The adhesive material used need not be limited to heat-activated type.Other types of adhesives that may be used include, without limitation,heat-activated adhesive laminate, two-sided adhesives with removablebacking, or the like.

Suitable material for adhering to the plurality of resilient elementsmay include without limitation, natural or synthetic fabric, mesh,flexible or pliable plastic, latex, silicone, or other rubber material,or made of synthetic fiber. As will be appreciated from the descriptionof the preferred embodiments below, this general process may be used toform various composite materials, including but not limited to compositepads with no reinforcement, partial reinforcement, full reinforcement,and both partial and full reinforcement of the resilient elements byresilient material.

Process for Making Resilient Elements

Referring now to the drawings, FIGS. 14-22 generally show the processfor cutting sheets of resilient and reinforcing materials to form cutsheets of resilient or reinforcing materials. FIG. 14 shows a sheet ofresilient material 110 positioned between a cutter 112 and a worksurface 114. The sheet of resilient material shown in FIG. 14 isdepicted in solid lines as an uncut sheet, whereas the dashed lines showhow the sheet of resilient material looks after it has been cut with thecutter in the manner described below. The sheet of resilient materialmay be made of such materials as foam, rubber, elastomer, plastic, andso forth (including any combination of such materials), and includes afirst side 116 and a second side 118 opposing the first side. Thematerial may be selected for various properties that make it aneffective pad for protective gear. For example, the material may beselected based on its resilience to impact, heat insulation properties,breathability, weight, ease of use in manufacturing, or any otherdesirable properties.

As an initial step in the process, an adhesive may be applied to thefirst side 116, and/or the second side 118 of the sheet of resilientmaterial 110 prior to cutting, although in a preferred embodiment,adhesive is applied to both sides. Any suitable means for applyingadhesive may be used, including a spray-on adhesive, roll-on adhesive,lamination, or the like. Likewise, any suitable adhesive may be used,including a heat-activated adhesive or laminate, two-sided adhesiveswith removable backing, etc.

After adhesive has been applied to the resilient material, the resilientmaterial may be cut in a desired and predetermined manner using acutter, such as cutter 112. The cutter may include a cutting surface 120for supporting various cutting edges or other structures. The cuttingsurface may be substantially planar for use in cutting resilient andreinforcing materials that are planar, or that are flexible and areconfigured in a planar shape beneath the cutter on a planar surface,such as a table or other work space. Alternatively or additionally, thecutting surface may be irregularly shaped for cutting resilient orreinforcing materials that are irregularly shaped, or that are flexibleand are configured in an irregular shape beneath the cutter on anirregularly shaped surface. For example, as shown in FIG. 14, the cuttermay be planar for use in cutting flexible resilient and reinforcingmaterials that are positioned on a planar work surface 114, where thework surface may additionally include a durable yet elastic overlay 122that prevents or inhibits dulling of cutting edges during operation. Forexample, the overlay may be made of plastic, nylon, rubber or any othersuitable material that prevents or inhibits dulling of cutting edgesduring operation.

As shown in FIGS. 14-20, the cutter 112 may include various cuttingedges for cutting resilient and reinforcing materials. For example, asshown in FIG. 14, the cutter may include a perimetral cutting edge 123extending from the cutting surface 120 and defining a boundary. Thisperimetral cutting edge may be sharpened at the end used for engagingand cutting materials, and may be shaped to cut materials into shapeshaving a desired border that corresponds to the shape of the boundarydefined by the perimetral cutting surface.

As shown in FIGS. 14-20, the cutter 112 may also include a plurality ofcutting elements 124 extending from the cutting surface to form apreselected pattern, each cutting element being sharpened at the endused for engaging and cutting materials. The cutting elements may bepositioned within the boundary defined by the perimetral cutting edge123, although any conceivable configuration of cutting elements may beprovided. Each cutting element is shaped to define an internal space 126corresponding to the desired shape of cut material. For example, cuttingelements may be substantially cylindrical for cutting cylindricallyshaped elements into materials, or may have irregular shapes for cuttingirregularly shaped elements into materials. The cutting elements may bespaced from one another so as to define a space between the cuttingelements. For example, in embodiments having both a perimetral cuttingedge and a plurality of cutting elements positioned in a pattern withinthe boundary defined by the perimetral cutting edge, the perimetralcutting edge and the cutting elements may define a contiguous space 128that surrounds the plurality of cutting elements and is within theboundary.

The internal spaces 126 and/or the contiguous space 128 may be filledwith a biasing material 130 to facilitate removal of cut portions of theresilient and/or reinforcing material from the internal spaces andcontiguous space. In some embodiments, both the internal spaces and thecontiguous space may be filled with biasing material to facilitateremoval of the cut portions from those spaces, and to facilitate keepingthe various portions of cut material in an assemblage, as will bedescribed in more detail below. In some embodiments, either the internalspaces or the contiguous space will be filled with biasing material tofacilitate removal of the cut portions from those spaces but to retainthe cut portions within the spaces that do not have any biasingmaterial. The biasing material may be a resilient material, including,either alone or in combination, foam, rubber, elastomer, plastic, etc.,and may be more or less resilient than the material to be cut. In someembodiments, the biasing material will be more resilient than thematerial being cut, to facilitate biasing of cut materials from thespaces containing the biasing material.

The biasing material used in the cutter may be made of any suitableresilient material that permits biasing of cut materials out of theinternal spaces and contiguous space defined by the cutting elementsand/or the perimetral cutting edge. The biasing material may be lessresilient than the resilient material, the reinforcing material, orboth. Selection of an appropriate biasing material requires littleexperimentation, and is within the capabilities of one of ordinary skillin the art.

It is understood that the biasing material used in the resilientmaterial cutting process may include any material or mechanism, whichserves to press the cut resilient element as the cut is made, so thatthe resilient element and the excess resilient material stay together onthe cut sheet and are not separated. Examples of such biasing materialmay include without limitation rubber or a spring mechanism.

As shown in FIGS. 14 and 15, the sheet of resilient material 110 ispositioned on the work surface 114, such as on the protective overlay122, between the work surface and the cutter 112. As shown in FIGS. 14and 16, the cutter is then pressed into the sheet of resilient material.This causes the cutting edges of the cutter (such as the perimetralcutting edge 123 shown in FIG. 14 and/or the plurality of cuttingelements 124 shown in FIGS. 14 and 16) and the biasing material 130(such as is in the internal spaces 126 and/or the contiguous space 128),to engage and compress the sheet of resilient material. During thiscompression process, the biasing material may also be compressed. Aspressure is increased by the cutter on the sheet of resilient material,the cutting edges cut through the material, thereby forming a cut sheetof resilient material 136 comprising a plurality of resilient elements138 and excess resilient material 40. Each resilient element has a firstside 42 and a second side 44 with the adhesive applied thereto, and ashape corresponding to the shape of the internal space 126 of itscorresponding cutting element. The plurality of resilient elements formsa pattern corresponding to the predetermined pattern of the plurality ofcutting elements. The excess resilient material has a shapecorresponding to the shape of the contiguous space 128. As such, forembodiments that include a cutter having a perimetral cutting edge 123that defines the outer boundary of the contiguous space, the excessresilient material will include a border 46 cut by the perimetralcutting edge (See FIG. 14).

After the cutting edges of the cutter 112 have cut completely throughthe sheet of resilient material, the cutter is withdrawn from the cutsheet of resilient material 136, as shown in FIGS. 14 and 17. The cutsheet of resilient material 136, including the plurality of resilientelements 138 and the excess resilient material 40, decompresses duringthis process. The biasing material 130 also decompresses, thereby urgingthe plurality of resilient elements and the excess resilient materialaway from the internal spaces 126 within, and the contiguous space 128surrounding, the plurality of cutting elements 124, to leave the cutsheet of resilient material with the cut portions of the resilientelements surrounded by the excess resilient material.

Process for Making Lattice of Reinforcing Material

A similar process is used to cut a sheet of reinforcing material as theresilient material, as shown in FIGS. 18-22. First, a sheet ofreinforcing material 47 is selected based on its desired properties. Thesheet of reinforcing material may be made of foam, neoprene, naturalleather, synthetic leather, plastic, or rubber (including withoutlimitation, latex and silicone, synthetic fabric, and so forth and anycombination of such materials), may have a different thickness from thesheet of resilient material, and may include the same or differentmaterial from the resilient material, and may have the same or differentfunctional properties from the resilient material. For example, thereinforcing material may be more or less resilient, rigid, flexible,stretchy, breathable, etc., than the resilient material.

As shown in FIG. 18, the sheet of reinforcing material 47 is positionedon the work surface 114, such as on the protective overlay 122, betweenthe work surface and the cutter 112. As shown in FIG. 19, the cutter isthen pressed into the sheet of reinforcing material, which causes thecutting edges of the cutter (such as the perimetral cutting edge 123shown in FIG. 14 and/or the plurality of cutting elements 124 shown inFIGS. 14 and 18) and the biasing material 130 (such as are in theinternal spaces 126 and/or the contiguous space 128), to engage andcompress the sheet of reinforcing material. As discussed above, thebiasing material may also be compressed during this compression process.As pressure is increased by the cutter on the sheet of reinforcingmaterial, the cutting edges cut through the material, thereby forming acut sheet of reinforcing material 48 comprising a plurality ofreinforcing elements 50 and a first lattice of reinforcing material 52having a shape which enables resilient elements to fit through the firstlattice of reinforcing material. Each reinforcing element has a shapecorresponding to the shape of the internal space 126 of itscorresponding cutting element. The plurality of reinforcing elementsforms a pattern corresponding to the predetermined pattern of theplurality of cutting elements. The first lattice of reinforcing materialhas a shape corresponding to the shape of the contiguous space 128. Assuch, for embodiments that include a perimetral cutting edge 123 thatdefines the outer boundary of the contiguous space, the first lattice ofreinforcing material will include a border 54 cut by the perimetralcutting edge (See FIG. 22).

It is to be noted that in one embodiment, if a particular partialreinforcement lattice is desired to be combined with a section ofresilient material, more than one perimetral cutting edge may beincorporated into the cutter to cut a sheet of reinforcement material,so that the design or the outer perimeter of the particular partialreinforcement lattice is defined by one of the perimetral cutting edgeson the cutter, and additional inner perimeters of the same partialreinforcement lattice is defined by one or more of the remainingperimetral cutting edges. Depending on the need, after the holes arepunched out in the sheet of reinforcement material, the resultinglattice of reinforcement material has been engaged to at least one ofthe resilient elements, and the fabric or mesh material or any othersuitable material has been adhered to the plurality of resilientelements to form the composite material, the particular partial latticethat is desired to be combined with the resilient elements may be madeby pulling or removing the undesired reinforcement material along theperimetral edges defining the boundary of the particular partialreinforcement lattice. Thus, the particular partial lattice ofreinforcement material or “partial cage” may be cut and may be combinedwith the resilient material. Several of these particular partialreinforcement lattices may be incorporated into a resilient pad,resulting in unique properties of the pad. Each of these partialreinforcement lattice may have different properties such as height,strength, resilience and so forth. A combination of these latticesimpart unique function to the composite pad.

After the cutting edges of the cutter 112 have cut completely throughthe sheet of reinforcing material, the cutter is withdrawn from the cutsheet of reinforcing material 48, as shown in FIG. 20. The cut sheet ofreinforcing material 48, including the plurality of reinforcing elements50 and the first lattice of reinforcing material 52, decompresses duringthis process. The biasing material 130 also decompresses, thereby urgingthe plurality of reinforcing elements and the first lattice ofreinforcing material away from the internal spaces 126 within, and thecontiguous space 128 surrounding, the plurality of cutting elements 124,to leave the cut sheet of reinforcing material with the cut portions ofthe reinforcing elements optionally surrounded by the first lattice ofreinforcing material. It is understood that the cut sheet of reinforcingmaterial 48 need not contain any reinforcing element as the reinforcingelement is discarded and therefore, the cut sheet of reinforcingmaterial does not intentionally preserve the reinforcing elementssurrounded by the lattice of reinforcing material.

It should be appreciated that the fully and partially reinforcedcomposite materials made by the present process only include latticesmade of the reinforcing material, and do not utilize the reinforcingelements cut by the cutter. As such, the first lattice of reinforcingmaterial 52 cut from the sheet of reinforcing material may be separatedfrom the reinforcing elements 50 and from any other leftover reinforcingmaterial, thereby leaving the first lattice of reinforcing material byitself, as shown in FIG. 21. The remaining first lattice of reinforcingmaterial 52, shown in FIGS. 21-22, thus includes a plurality of holes 56through the reinforcing material where the reinforcing elements used tobe, and may also include a border 54, such as is cut by a perimetralcutting edge 123.

Assembling Resilient Pad Using a Die

After forming the cut sheet of resilient material 136 (including theplurality of resilient elements 138 and the excess resilient material40), and the first lattice of reinforcing material 52, the first latticeof reinforcing material is assembled with the plurality of resilientelements to form a resilient material assembly using a die 58 and apusher 60, according to the process shown in FIGS. 23-27.

As shown in FIG. 23, the die 58 includes a surface 62 having a pluralityof openings 64 defined therein, where the surface surrounding theopenings has a shape corresponding to the shape of the excess resilientmaterial 40 in the cut sheet of resilient material 136, andcorresponding to the shape of the first lattice of reinforcing material52, and the plurality of openings form a pattern corresponding to thepattern of the resilient elements 138 in the cut sheet of resilientmaterial 136. The pusher includes a pushing surface 66 and a pluralityof push elements 68 that extend from the push surface and form a patterncorresponding to the pattern of the resilient elements in the cut sheetof resilient material.

As shown in FIG. 24, the first lattice of reinforcing material 52 isplaced on the die, and is aligned so that the plurality of holes 56 inthe first lattice of reinforcing material are positioned above theplurality of openings 64 in the die 58. Next, the cut sheet of resilientmaterial 136 is placed on top of the first lattice of reinforcingmaterial, and is aligned so that the plurality of resilient elements 138are positioned above the plurality of holes 56 in the first lattice ofreinforcing material, and above the plurality of openings 64 in the die.Finally, the pusher 60 is positioned above the die, the lattice ofreinforcing material, the cut sheet of resilient material, and thepusher is aligned so that the plurality of push elements are alignedwith and oriented towards the plurality of resilient elements 138.

As shown in FIG. 25, the pusher 60 is then lowered until the pluralityof push elements 68 engage with the plurality of resilient elements 138,whereby the resilient elements are pushed out of the excess resilientmaterial 40 to a position where they are partially in the plurality ofholes 56 in the first lattice of reinforcing material 52 and partiallyin the plurality of openings 64 in the die 58. As such, the cut portionsof the plurality of resilient elements are at least partially surroundedby the first lattice of reinforcing material.

As shown in FIG. 26, the excess resilient material 40 is removed fromthe die and discarded. The remaining plurality of resilient elements 138and the lattice of reinforcing material 52 have now been assembled toform a resilient material assembly 70, where the first sides 116 of theplurality of resilient elements define a first side 72 of the resilientmaterial assembly, and the second sides of the plurality of resilientelements 118 define a second side of the resilient material 74 assemblyopposite the first side of the resilient material assembly. As shown inFIG. 27, the resilient material assembly 70 is then removed from the die58 so that it can be used as a substrate for forming various compositematerials.

FIGS. 28-44 show various additional processes for forming compositematerials starting from the resilient material assembly 70, which asdiscussed above, includes the plurality of resilient elements 138 andthe first lattice of reinforcing material 52. The steps shown in FIGS.28-44 show the process for forming composite materials from resilientmaterial assembly 70 where the resilient elements 138 have aheat-activated adhesive bonded to their surfaces. It is understood thatsimilar method steps could be used to assemble substantially similarcomposite materials from a resilient material assembly 70 where theresilient elements 138 have a different type of adhesive bonded to theiropposing surfaces, but such method steps would not require theapplication of heat to bond the various elements of the compositematerials together.

As shown in FIG. 28, the resilient material assembly is placed on asurface beneath a heat platen 76. A first sheet of fabric or meshmaterial 78 is placed onto the first side 72 of the resilient materialassembly so that the first fabric or mesh sheet contacts the first sides116 of the plurality of resilient elements. As shown in FIG. 29, theheat platen is lowered until it contacts the first fabric or mesh sheet,and is then heated, thereby heating the first fabric or mesh materialand the first side of the resilient material assembly. This activatesthe adhesive on the first sides of the plurality of resilient elements,whereby the first fabric or mesh material is adhered to the first sideof the resilient material assembly to form a first composite material80. As shown in FIG. 30, the first composite material is then removedfrom the heat platen for further processing. Alternatively oradditionally, the first composite material shown in FIG. 30 can be usedas a protective pad without further processing.

It should be understood that the first lattice of reinforcing material52 in the first composite material 80 is not adhered or otherwisepermanently secured to the plurality of resilient elements 138. As such,the first lattice of reinforcing material can be easily removed from theplurality of resilient elements, as shown in FIG. 31, to form a secondcomposite material 82 having the first fabric or mesh sheet 78 adheredto the first sides of the plurality of resilient elements, but lacking areinforcement lattice altogether. After the first lattice of reinforcingmaterial has been removed from the plurality of resilient elements toform the second composite material, the first fabric or mesh sheetsubstantially retains the plurality of resilient elements in apredetermined pattern. Alternatively, if a sheet of reinforcing materialis cut with a cutter with multiple perimetral cutting edges, the excessmaterial outside the desired defined area may be removed from the sheetof reinforcing material, leaving a “partial cage”, resulting in thefourth composite material.

The second composite material 82 can be used as a substrate to make yetother composite materials. For example, as shown in FIGS. 32-34, thesecond composite material 82 can be used to make a third compositematerial 84 comprising the plurality of resilient elements 138sandwiched on opposite sides by the first fabric or mesh sheet 78 and asecond fabric or mesh sheet 86, but lacking a reinforcement latticealtogether. To make this third composite material, the second compositematerial 82 is placed beneath the heat platen 76 with the first sides ofthe resilient elements 116 and the first fabric or mesh sheet 78 facingaway from the heat platen, and the second sides of the resilientelements 118 facing the heat platen. A second fabric or mesh sheet 86 isthen placed onto the second side of the resilient elements, and isheated with the heat platen to activate the adhesive on the second sidesof the plurality of resilient elements, whereby the second fabric ormesh sheet adheres to the second sides of the plurality of resilientelements to form the third composite material 84. Because the firstlattice of reinforcing material was removed from the plurality ofresilient elements prior to adhering the second fabric or mesh sheet tothe resilient elements, this third composite material lacks areinforcement lattice altogether. The third composite material may beused as a protective pad.

As shown in FIGS. 35-38, the second composite material 82 can also beused to make a fourth composite material 88 comprising the plurality ofresilient elements 138 sandwiched between a pair of fabric or meshsheets 78 and 86, and one or more lattices of reinforcing material 90that each surround only a subset of the plurality of resilient elements.In such cases, the first lattice of reinforcing material 52 that wasremoved from the first composite material 80 (see FIGS. 30-31) can becut to a smaller desired shape to form a second lattice of reinforcingmaterial 90 that will only surround a subset of the plurality ofresilient elements. Alternatively or additionally, one or more latticesof reinforcing material 90 smaller than the first lattice of reinforcingmaterial 52 can be made from scratch according to the general steps forcutting a lattice of reinforcing material described above. As shown inFIGS. 35-36, one or more of these smaller lattices of reinforcingmaterial 90 can be pressed onto a desired subset of the plurality ofresilient elements 138 so that only portions of the plurality ofresilient elements are reinforced by a lattice or lattices ofreinforcing material. As shown in FIGS. 36-38, after pressing thesmaller lattice of reinforcing material onto the desired subset ofresilient elements, a heat platen 76 can be used to adhere a secondfabric or mesh sheet 86 to the second sides 118 of the resilientelements to form the fourth composite material 88.

The first composite material 80 shown in FIG. 30 also can be used as asubstrate to make other composite materials. For example, as shown inFIGS. 39-41, the first composite material 80 can be used to make a fifthcomposite material 92 comprising the plurality of resilient elements 138sandwiched on opposite sides by fabric or mesh sheets 78 and 86, andsurrounded by the first lattice of reinforcing material 52. To make thisfifth composite material, the first composite material is placed beneaththe heat platen with the first sides of the resilient elements 116 andthe first fabric or mesh sheet 78 facing away from the heat platen 76,and the second sides of the resilient elements facing the heat platen. Asecond fabric or mesh sheet 86 is then placed onto the second side 118of the resilient elements, and is heated with the heat platen toactivate the adhesive on the second sides of the plurality of resilientelements, whereby the second fabric or mesh material adheres to thesecond sides of the plurality of resilient elements to form the fifthcomposite material 92. Because the first reinforcement lattice 52 wasnever removed from the plurality of resilient elements 138 prior toadhering the second fabric or mesh sheet to the resilient elements, thisfifth composite material includes a reinforcement lattice that fullysurrounds the plurality of resilient elements.

As shown in FIGS. 42-44, the first composite material 80 also can beused to make a sixth composite material 94 comprising the plurality ofresilient elements 138 sandwiched on opposite sides by fabric or meshsheets 78, 86, where all of the resilient elements are surrounded by thefirst lattice of reinforcing material 52, and one or more subsets of theresilient elements are surrounded by one or more second smaller latticesof reinforcing material 90. To make this sixth composite material, oneor more lattices of reinforcing material 90 that are smaller than thefirst excess resilient material 52 can be made from scratch according tothe general steps discussed above or a piece taken from an existinglattice, which may be pre-designed to be broken off. The smallerlattice(s) of reinforcing material then can be pressed onto any desiredsubset(s) of resilient elements 138 so that each smaller lattice onlysurrounds that subset. After pressing the smaller lattice(s) ofreinforcing material onto the desired subset(s) of resilient elements, aheat platen 76 can be used to adhere a second fabric or mesh sheet 86 tothe sides of the resilient elements opposite to the side adhered to thefirst fabric or mesh sheet 78 in the manner discussed above. This formsthe sixth composite material 94, which can be used as a protective pad.

In another embodiment, a layer of mesh or fabric or any other suitablematerial may be placed in the die so that when the resilient elementsare pushed through with a pusher 60, the resilient elements contact andbind directly to the mesh or fabric or any other suitable material.

A Second Process for Making the Resilient Composite Pad

An alternative process for making various composite pads with noreinforcement, partial reinforcement, full reinforcement, and bothpartial and full reinforcement generally comprises:

(a) providing a sheet of resilient material having opposing sides;

(b) applying an adhesive to either or both sides of the sheet ofresilient material;

(c) providing a first cutter having a surface and a plurality of cuttingelements extending from the surface in a predetermined pattern, whereeach cutting element has a shape defining an internal space, wherein theplurality of cutting elements are spaced apart from one another todefine a contiguous space surrounding and between the plurality ofcutting elements, and the internal spaces and the contiguous space arefilled with biasing material;

(d) pressing the first cutter into the sheet of resilient material,thereby forming a cut sheet of resilient material comprising a pluralityof resilient elements and excess resilient material, wherein eachresilient element has a shape corresponding to the shape of the internalspace of its corresponding cutting element, the plurality of resilientelements form a pattern corresponding to the predetermined pattern ofthe plurality of cutting elements, and the excess resilient material hasa shape corresponding to the shape of the contiguous space;

(e) withdrawing the first cutter from the cut sheet of resilientmaterial, whereby the biasing material urges the plurality of resilientelements and the excess resilient material away from the internal spaceswithin and the contiguous space surrounding the plurality of cuttingelements, thereby leaving the cut sheet of resilient material with thecut portions of the resilient elements surrounded by the excessresilient material;

(f) providing a sheet of reinforcing material, which may be optionallyprocessed using the following methods however, the methods of processinga reinforcement lattice is not limited to carrying out the followingsteps, so long as at least one reinforcement lattice is obtained so asto be combinable with the resilient elements to form the inventivecomposite pad;

(g) pressing a second cutter into the sheet of reinforcing material,thereby forming a cut sheet of reinforcing material comprising aplurality of reinforcing elements and a lattice of reinforcing material,wherein each reinforcing element has a size and shape corresponding tothe predetermined size and shape of the cutting elements, the pluralityof reinforcing elements form a pattern corresponding to thepredetermined pattern of the plurality of cutting elements, and thelattice of reinforcing material has a shape corresponding to the shapeof the contiguous space;

(h) withdrawing the second cutter from the cut sheet of reinforcingmaterial, whereby if the biasing material is optionally used, thebiasing material urges the plurality of reinforcing elements and thelattice of reinforcing material away from the internal spaces within andthe contiguous space surrounding the plurality of cutting elements, andthereby leaves the cut sheet of reinforcing material with the cutportions of the reinforcing elements optionally surrounded by thelattice of reinforcing material;

(i) separating the lattice of reinforcing material from the reinforcingelements, whereby the lattice of reinforcing material is left with aplurality of holes through the reinforcing material where thereinforcing elements used to be;

(j) removing adhesive layer from the excess resilient material on thefirst side of the cut sheet of resilient material, leaving adhesive onthe resilient elements;

(k) bonding a first substrate such as a fabric or mesh to the first sideof the cut sheet of resilient material resulting in bonding between theresilient elements to the first substrate optionally by contacting theresilient material with a heat platen, if heat-activated adhesivematerial was applied to the first side of the resilient material;

(l) separating the excess resilient material from the cut sheet ofresilient material, leaving the plurality of resilient elements bound tothe first substrate;

(m) engaging the holes of the lattice of reinforcing material to theplurality of resilient elements to form the composite material;

(n) placing a second substrate such as a sheet of fabric or meshmaterial or any other suitable material onto the second side of theresilient material so that the plurality of resilient elements on thesecond side of the resilient material bond to the second substrate; and

(o) heating the second fabric or mesh sheet substrate or any othersuitable material with a heat platen to activate the adhesive on theplurality of resilient elements on the second side of the resilientmaterial, whereby the second fabric or mesh material or any othersuitable material adheres to the plurality of resilient elements to forma composite material, if heat-activated adhesive material was applied tothe second side of the resilient material.

It is to be understood that the adhesive material used need not belimited to heat-activatable type. Other types of adhesives that may beused including without limitation, heat-activated adhesive laminate,two-sided adhesives with removable backing, or the like.

Suitable material for the substrate to which the plurality of resilientelements are adhered may include without limitation, natural orsynthetic fabric, mesh, flexible or pliable plastic, latex, silicone, orother rubber material, or made of synthetic fiber.

As will be appreciated from the description of the preferred embodimentsbelow, this general process may be used to form various compositematerials, including but not limited to composite pads with noreinforcement, partial reinforcement, full reinforcement, and bothpartial and full reinforcement of the resilient elements by reinforcingmaterial.

It should also be understood that the adhesive layer may be applied toone or both sides of the cut sheet of resilient material. Thereinforcing material, including the lattice portion, may also beoptionally coated with an adhesive layer on either one or both sides ifa permanent bonding between the lattice of reinforcing material and thefirst substrate is desired.

It is also contemplated that in the scheme of things, the resilientmaterial may be composed of different types of material or color, whichmay be secured to a single continuous lattice of reinforcing material.Conversely, several lattices of reinforcing material may be used tosecure a resilient material of a single continuous material. Also,several types of resilient material may be linked together and assembledwith several different types of lattices of reinforcing material.

The cutting of the resilient material is described above. However, forpurposes of usage in the second process for making the resilientcomposite pad the resilient elements are not to be “pushed out” in adie.

The lattice of reinforcing material may be made as described above foruse in the second process for making the resilient composite pad.Alternatively, the lattice of reinforcing material may be made by simplycutting a resilient material with a cutter.

Assembling Pad Composite Without the Need for Use of a Die

After forming the cut sheet of resilient material 136 (including theplurality of resilient elements 138 and the excess resilient material40), and the first lattice of reinforcing material 52, the plurality ofresilient elements 138 are bonded to the first fabric or mesh sheet“substrate” 78. The excess resilient material is removed. Then, thefirst lattice of reinforcing material is assembled with the plurality ofresilient elements to form a resilient material assembly by fitting thefirst lattice of reinforcing material 52 on to the group of resilientelements, according to the process shown in FIGS. 46-49 and 62-68. Asshown in FIG. 14, the cut resilient material includes a first side 116and second side 118. At least one of the surfaces is coated with anadhesive.

In one embodiment of the invention, the adhesive on the excess resilientmaterial is removed. The removal may be carried out in a variety ofways. In one aspect, the adhesive layer coating the excess resilientmaterial may be “pulled off” of the resilient material leaving behindthe adhesive layer bound only on the resilient element. This procedureresults in the resilient elements 138 being coated with adhesive and theexcess resilient material 40 not being coated with adhesive on the firstside 116 of the cut resilient material. This is illustrated in FIGS. 45and 60-61. In a specific embodiment of the invention, the resilientmaterial is pre-coated with a heat activated adhesive such as hot meltadhesive or film appropriate for EVA (ethylene vinyl acetate) or similartype of plastic, foam or rubber.

To elaborate further on the desirability of ultimately bonding only theresilient element portion of the cut sheet of resilient material to thefirst substrate, FIGS. 45 and 60-61 show an exemplified method asillustrated, of coating the entire resilient material with adhesivebefore cutting the resilient material, and then physically pulling offor chemically dissolving the adhesive material bound only to the excessresilient material portion, leaving behind adhesive material on theresilient elements, which is bonded to the first substrate.

Other methods to selectively coat the resilient elements may includewithout limitation, using masks to activate or directly apply theadhesive only on the resilient elements. For instance, adhesive may beapplied only to the resilient elements 138 by the use of a mask thatcovers the excess resilient material 40 so as to apply the adhesivematerial selectively, rather than to the entire surface of the resilientmaterial. This would save on the cost of adhesives. The adhesive may beapplied to a cut sheet of resilient material, or alternatively, to apre-cut but pre-marked sheet of resilient material.

Alternatively, chemically treated masks may also be used to deactivateor remove or “etch out” the adhesive on the excess resilient material.Or, the excess resilient material portion coated with adhesive may be“covered” prior to contacting the first substrate to the resilientelements in order to prevent adhesion of the excess resilient materialto the substrate. For example, a sheet of wax paper with holes cut outto accommodate the resilient elements may be aligned. Such “blocking”paper may sit between the resilient material and the substrate duringlamination, and prevent the excess resilient material from adhering tothe substrate.

A first substrate 78 such as a fabric or mesh is contacted with thefirst side 116 of the cut resilient material in particular the adhesivecoated resilient elements 138, and the bonding between the resilientelements 138 and the substrate 78 is allowed to occur. Once the bondinghas occurred, the excess resilient material 40 is removed from theresilient material, leaving the resilient elements 138 of the first side116 bonded to the first substrate 78, and the second side of theresilient elements 44 optionally coated with an adhesive. This compositeassembly is referred to herein as the second composite material 302(FIGS. 45-48 and 62-63).

In one aspect of the invention, the plurality of resilient elements 138bonded to the first substrate 78 is aligned with the first lattice ofreinforcing material 52 so that the plurality of resilient elements 138are positioned in alignment with the plurality of holes 56 in the firstlattice of reinforcing material 52 (FIGS. 49 and 67-68). In anotheraspect, the plurality of resilient elements 138 are forced to a positionwhere they are at least partially in the plurality of holes 56 in thefirst lattice of reinforcing material 52. As such, the plurality ofresilient elements are at least partially surrounded by the firstlattice of reinforcing material.

Alternatively and additionally, the plurality of resilient elements 138bonded to the first substrate 78 may be aligned with a second lattice ofreinforcing material 90 so that the second lattice of reinforcingmaterial surrounds only a subset of the plurality of resilient elements(FIGS. 53 and 64-70).

The plurality of resilient elements 138 and the lattice of reinforcingmaterial 52 have now been assembled to form a resilient materialassembly, where a first side of the plurality of the resilient elements42, coated with adhesive is bonded to the first substrate and the secondside of the plurality of resilient elements 44 defines a second side ofthe resilient material opposite the first side of the resilient materialassembly (FIG. 68). The plurality of resilient elements on the secondside 44 may be bonded to a second substrate opposite the first side ofthe resilient material assembly (FIGS. 56, 59 and 71).

Assembly Of Composite Using the Second Process For Making the ResilientComposite Pad Material In Greater Detail

FIGS. 46-59 show processes for forming composite materials in greaterdetail. The steps shown in FIGS. 46-59 show the process for formingcomposite materials where the resilient elements 138 have aheat-activated adhesive bonded to their surfaces. It is understood thatsimilar adhesive may be used to assemble similar composite materialswhere the resilient elements 138 are coated with a type of adhesive thatwould not require the application of heat to bond the various elementsto a substrate.

As shown in FIG. 46, the cut sheet of resilient material 136, in whichonly the resilient elements 138 are coated with adhesive on the firstside of the resilient material 116 are placed on a surface next to aheat platen 76. A first substrate or sheet of fabric or mesh material 78is placed onto the first side of the resilient material 116 so that thefirst substrate of fabric or mesh sheet contacts the first side of theplurality of resilient elements 42 coated with adhesive. It is notedthat the excess resilient material 40 is not coated with adhesive asdescribed above or may be coated but may be covered with a material thatprevents the excess material portion from contacting or bonding to thesubstrate 78. As shown in FIG. 47, a heat platen is moved towards thefirst substrate of fabric or mesh sheet 78, until it contacts the firstsubstrate of fabric or mesh sheet, and is then heated, or alternativelyand optionally the heat platen is pre-heated before it contacts thesubstrate of fabric or mesh sheet, thereby heating the first substrateof fabric or mesh material and the first side of the resilient material116. This activates the adhesive on the first side of the plurality ofresilient elements 42, whereby the first substrate of fabric or meshmaterial is adhered to the first side of the resilient material 116 toform a resilient material/substrate composite material 300 (FIG. 47).

As shown in FIG. 48, the resilient material/substrate composite material300 is then removed from the heat platen for further processing. Asshown in FIGS. 48 and 62, the excess resilient material 40 is removedfrom the resilient material/substrate composite material 300 resultingin a second composite material 302, which includes a substrate bonded toresilient elements. Alternatively or additionally, the second compositematerial 302 shown in FIGS. 48 and 63 can be used as a protective padwithout further processing.

Alternatively or additionally, the holes of a first reinforcementlattice are aligned to the plurality of resilient elements 138 and aresecured or engaged to result in the first composite material 301 (FIGS.49 and 67-68).

Alternatively or additionally, after the holes of a first reinforcementlattice are aligned to the plurality of resilient elements 138 and areinserted or engaged, the reinforcement lattice may be optionally gluedto the first substrate, resulting in a type of composite material thatcan be used as a protective pad without further processing.

However, it should be understood that the first lattice of reinforcingmaterial 52 in the first composite material 301 is preferably notadhered or otherwise permanently secured to the plurality of resilientelements 138. As such, the first lattice of reinforcing material may beloosely inserted, secured, engaged or fitted to the plurality ofresilient elements.

The second composite material 302 can be used to make yet othercomposite materials. For example, as shown in FIGS. 50-52, the secondcomposite material 302 can be used to make a third composite material303 comprising the plurality of resilient elements 138 sandwiched onopposite sides by the first fabric or mesh sheet substrate 78 and asecond fabric or mesh sheet substrate 86, but lacking a lattice ofreinforcing material. To make this third composite material, the secondcomposite material 302 is placed next to the heat platen 76 with thefirst sides of the resilient elements 42 and the first fabric or meshsheet 78 facing away from the heat platen, and the second sides of theresilient elements 44 facing the heat platen. A second fabric or meshsheet substrate 86 is then placed onto the second side of the resilientelements, and is heated with the heat platen to activate the adhesive onthe second sides of the plurality of resilient elements, whereby thesecond fabric or mesh sheet adheres to the second sides of the pluralityof resilient elements to form the third composite material 303, whichlacks excess resilient material or reinforcing material. This thirdcomposite material type also may be used as a protective pad withoutfurther processing.

As shown in FIGS. 53-56 and 64-66, the second composite material 302 canalso be used to make a fourth composite material 304 comprising theplurality of resilient elements 138 sandwiched between a pair of fabricor mesh sheet substrates 78 and 86, and one or more lattices ofreinforcing material 90 that surround only a subset of the plurality ofresilient elements. In such cases, the first lattice of reinforcingmaterial can be cut to a smaller desired shape to form a second latticeof reinforcing material 90 that will only surround a subset of theplurality of resilient elements. Alternatively or additionally, one ormore lattices of reinforcing material 90 smaller than the first latticeof reinforcing material 52 can be made from scratch according to thegeneral steps for cutting a lattice of reinforcing material describedabove. As shown in FIGS. 53-54 and 64-66, one or more of these smallerlattices of reinforcing material 90 can be pressed onto a desired subsetof the plurality of resilient elements 138 so that only portions of theplurality of resilient elements are reinforced by a lattice or latticesof reinforcing material. As shown in FIGS. 53-56, 64-66 and 71, afterpressing the smaller lattice of reinforcing material onto the desiredsubset of resilient elements, a heat platen 76 can be used to adhere asecond fabric or mesh sheet substrate 86 to the second sides 118 of theresilient elements to form the fourth composite material 304.

As shown in FIGS. 57-59, 69 and 70, the first composite material 301also can be used to make a sixth composite material 306 comprising theplurality of resilient elements 138 sandwiched on opposite sides byfabric or mesh sheet substrates 78, 86, where all of the resilientelements are surrounded by the first lattice of reinforcing material 52,and one or more subsets of the resilient elements are surrounded by oneor more second smaller lattices of reinforcing material 90. To make thissixth composite, one or more lattices of reinforcing material 90 thatare smaller than the first lattice of reinforcing material 52 can bemade from scratch according to the general steps discussed above. Thesmaller lattice(s) of reinforcing material then can be pressed onto anydesired subset(s) of resilient elements 138 so that each smaller latticeonly surrounds that subset. After pressing the smaller lattice(s) ofreinforcing material onto the desired subset(s) of resilient elements, aheat platen 76 can be used to adhere a second fabric or mesh sheetsubstrate 86 to the sides of the resilient elements opposite the sideadhered to the first fabric or mesh sheet substrate 78 in the mannerdiscussed above. This forms the sixth composite material 306, which canbe used as a protective pad. Moreover, multiple smaller lattices ofreinforcing material may be layered on to subsets of resilient elements.

In another aspect of the invention, the fabric or mesh sheets 78 and/or86 may be natural or synthetic fibers. Alternatively, the sheetingstructure may be flexible or pliable plastic, or latex, silicone, orother rubber material, or made of synthetic fiber.

The various components of the process disclosed herein may be made ofany suitable material and may be any size and shape consistent withtheir functions. The specific embodiments of the process disclosed andillustrated herein are not to be considered in a limiting sense asnumerous variations are possible. Ordinal indicators, such as first,second or third, for identified elements in the specification or theclaims are used to distinguish between the elements, and do not indicatea required or limited number of such elements, and do not indicate aparticular position or order of such elements unless otherwisespecifically indicated. The subject matter of this disclosure includesall novel and non-obvious combinations and subcombinations of thevarious features, elements, functions and/or properties disclosedherein. No single feature, function, element or property of thedisclosed embodiments is essential.

The present invention is not to be limited in scope by the specificembodiments described herein. Indeed, various modifications of theinvention in addition to those described herein will become apparent tothose skilled in the art from the foregoing description and accompanyingfigures. Such modifications are intended to fall within the scope of theappended claims. The following examples are offered by way ofillustration of the present invention, and not by way of limitation.

Those skilled in the art will recognize, or be able to ascertain usingno more than routine experimentation, many equivalents to the specificembodiments of the invention specifically described herein. Suchequivalents are intended to be encompassed in the scope of the claims.

1. A composite pad structure comprising a substrate bonded to aplurality of discrete, spaced-apart, resilient elements engaged to atleast one floating reinforcing structure.
 2. The composite pad structureaccording to claim 1, wherein the reinforcing structure comprises alattice of reinforcing material.
 3. The composite pad structureaccording to claim 2, wherein the lattice of reinforcing materialengages all of the resilient elements.
 4. The composite pad structureaccording to claim 2, wherein the lattice of reinforcing materialengages some of the resilient elements.
 5. The composite pad structureaccording to claim 2, wherein at least one lattice of reinforcingmaterial engages all of the resilient elements, and additional latticeof reinforcing material engages some of the resilient elements.
 6. Thecomposite pad according to claim 1, wherein a second substrate is bondedon opposite side of the resilient elements.
 7. The composite padaccording to claim 1, wherein the resilient elements engaged to thereinforcing structure is positioned between the first and secondsubstrates.
 8. A support comprising the composite according to claim 1.9. The support according to claim 8, which is an athletic garment,footwear, bag, backback, sack, seating pads, or athletic equipment. 10.An athletic safety wear, comprising the composite according to claims 1.11-33. (canceled)